Mercury MERCRUISER User guide

Gasoline Inboard Models
©2006, Mercury Marine. All rights reserved. Printed in U.S.A. 90-863758060 AUGUST 2006
Product Applications Manual
Product Applications Manual - Gasoline Inboard Models 90-863758060
www.mercurymarine.com.au
Private Bag 1420
Dandenong South 3175
Victoria, Australia
www.mercurymarine.com
P.O. Box 1939
Fond du Lac, WI 54936-1939 USA
www.marinepower.com
(Parc Industriel de Petit-Rechain)
B-4822 Verviers/Belgium NOTICE
Details for specific product installation are located in the Power
Package Installation Manual that accompanies each product.
90-863758060cvr.qxp 8/31/2006 3:21 PM Page 1

Page i
Manual Introduction and Overview
This Product Applications Manual has been written and published by Mercury Marine and
is targeted to the boat manufacturer's engineers and designers. It is intended to aid you,
the boat manufacturer, in the proper integration of our power packages in your boats.
Proper integration is critical to extract the full potential from your boat and engine packages
and to deliver our mutual customers the reliability, durability, and performance that exceed
their expectations.
The manual includes important information, recommendations, and requirements for
designing your boats and setting up your assembly process to optimize the installation of
our products. Laid out by system (i.e. fuel system, exhaust system), the manual allows the
user to quickly locate important information about the systems that comprise the power
package installation. It is not intended to replace the installation manuals (provided with
the engines), which cover step-by-step installation procedures for the power package
hardware. Your installers should still use the installation manuals when installing the power
packages to ensure that no steps are missed and all cautions and warnings are understood.
We cannot anticipate all conceivable installations and their possible hazards or results.
Therefore, any manufacturer or person who applies or installs the product in a manner that
does not fulfill the requirements listed herein must first be completely satisfied that neither
their safety nor the product will be endangered by the application or installation procedure
selected.
The boat manufacturer or installing dealer is responsible for selecting the appropriate
power package (including correct gear ratio and propeller) for a given boat. Making an
appropriate selection requires knowledge of the boat (weight, length, hull design, intended
use and duty cycle, desired speed, etc.) that is uniquely in the possession of the boat
manufacturer or installing dealer. While Mercury employs people capable of assisting on
such issues, the final decision on the application of the product rests with the boat
manufacturer or installing dealer. Mercury recommends that any new or modified hull–
power package combination be thoroughly tested prior to sale to verify that the boat
performs as desired, handles safely, and that the engine runs in the specified RPM range.
All information, illustrations, and specifications contained in this manual are based on the
latest product information available at the time of publication. Mercury MerCruiser reserves
the right to make changes at any time without obligation. As required, revisions to this
manual will be made available. Any suggested improvements to this manual are welcome
and should be directed to:
Mercury MerCruiser, Technical Communication Department
3003 N. Perkins Road,
Stillwater, OK 74075
405-377-1200
Fax [phone]
Safety Alerts and Notices
Throughout this publication, "Warnings" and "Cautions," accompanied by the international
HAZARD symbol !, are used to alert the technician to special instructions concerning
a particular service or operation that may be hazardous if performed incorrectly or
carelessly. Observe these safety alerts carefully.
These safety alerts alone can not eliminate the hazards they signal. Strict compliance to
these special instructions when performing the service, and common sense operation are
major accident prevention measures.

Page ii
! WARNING
WARNING—indicates a potentially hazardous situation that, if not avoided, could result
in death or serious injury.
! CAUTION
CAUTION—indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury or property damage. It may also be used to alert against unsafe
practices.
IMPORTANT: Indicates information or instructions that are necessary for a particular step
or action.
NOTE: Indicates information that helps in the understanding of a particular step or action.
Related Bulletin List
Use the following table to record any future bulletins that affect or add to the information in
this manual. List the bulletin numbers and affected sections or pages in this manual for
your reference.
Bulletin Type Bulletin Number Bulletin Description/Title Section/Page
Affected
Copyright and Trademark Information
Mercury Marine, Fond du Lac, Wisconsin U.S.A.
Litho in U.S.A.
© 2006, Mercury Marine
Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury
Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo,
Pro Max, OptiMax, Sport-Jet, K-Planes, MerCathode, RideGuide, SmartCraft, Zero Effort,
M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered
trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered
service mark of Brunswick Corporation.

Page iii
Manual Outline
1 - Important Information
A - Important Information
2 - Transmission and Drive Line
A - Transmission and Drive Line
3 - Engine
A - Engine
4 - Air Intake System
A - Air Intake System
5 - Fuel Delivery System
A - Fuel Delivery System
6 - Exhaust System
A - Exhaust System
7 - Cooling System
A - Cooling System
8 - Electrical System
A - Electrical System
9 - Instrumentation and Controls
A - Instrumentation and Controls
10 - Predelivery Preparation
A - Predelivery Preparation
Important Information 1
Transmission and Drive Line 2
Engine 3
Air Intake System 4
Fuel Delivery System 5
Exhaust System 6
Cooling System 7
Electrical System 8
Instrumentation and Controls 9
Predelivery Preparation 10

Page iv

Important Information
90-863758060 AUGUST 2006 Page 1A-1
1
A
Important Information
Section 1A - Important Information
Table of Contents
Sales and Technical Assistance......................1A-2
Inside the U.S.A. ......................................1A-2
Outside the U.S.A.....................................1A-2
Mercury MerCruiser Service Offices.........1A-2
Mercury Precision Parts / Quicksilver Products
.........................................................................1A-3
Factory Installed Options.................................1A-3
Serial Number Decal Placement—Inboard and Tow
Sports...............................................................1A-4
California Regulations for 2007—Low Permeation
Fuel Hose.........................................................1A-4
Emission Control Information...........................1A-5
International Regulations Compliance......1A-5
Emission Control Information Label..........1A-5
Star Label.................................................1A-8
Specifications.................................................1A-10
Engine Specifications.............................1A-10
Torque Specifications.............................1A-13

Important Information
Page 1A-2 90-863758060 AUGUST 2006
Sales and Technical Assistance
Mercury MerCruiser employs a staff of highly trained specialists to assist you with any sales
or technical issues that you might have. This includes a group of Product Application
Engineers (PAEs) who specialize in the application of our product and are recognized
throughout the industry for their expertise in this area. If you have an issue with the
application of our product that cannot be resolved over the telephone, an PAE can be
scheduled to assist you at your facility. All requests for assistance should be directed to:
Inside the U.S.A.
Mercury MerCruiser
3003 N. Perkins Rd.
Stillwater,, OK 74075
Quality/Service Support
,
[phone]
Fax [phone]
Sales or Field Sales Technical Support
,
[phone]
Fax [phone]
Outside the U.S.A.
Contact your Distribution Center or Distributor.
Mercury MerCruiser Service Offices
For assistance, call, fax, or write. Please include your daytime telephone number with mail
and fax corresponce.
United States
Telephone (405) 743‑6555 Mercury MerCruiser
3003 N. Perkins Road
Stillwater, OK 74074
Fax (405) 743‑6570
Website www.mercurymarine.com
Canada
Telephone (905) 567‑6372 Mercury Marine Ltd.
2395 Meadowpine Blvd.
Mississauga, Ontario L5N 7W6
Canada
Fax (905) 567‑8515
Australia, Pacific
Telephone (61) (3) 9791‑5822 Mercury Marine Australia
132–140 Frankston Road
Dandenong, Victoria 3164
Australia
Fax (61) (3) 9793‑5880
Europe, Middle East, Africa
Telephone (32) (87) 32 • 32 • 11 Marine Power — Europe, Inc.
Parc Industriel de Petit-Rechain
B-4800 Verviers,
Belgium
Fax (32) (87) 31 • 19 • 65

Important Information
90-863758060 AUGUST 2006 Page 1A-3
Mexico, Central America, South America, Caribbean
Telephone (954) 744‑3513 Mercury Marine
11650 Interchange Circle North
Miramar, FL 33025
U.S.A.
Fax (954) 744‑3535
Japan
Telephone 81‑053‑423‑2500 Mercury Marine — Japan
Anshin-cho 283-1
Hamamatsu
Shizuoka-ken, Japan 435-0005
Japan
Fax 81‑053‑423‑2510
Asia, Singapore
Telephone [phone] Mercury Marine Singapore
72 Loyang Way
Singapore, 508762
Fax [phone]
Mercury Precision Parts / Quicksilver Products
A complete line of Quicksilver Accessories (remote controls, instrumentation, exhaust and
cooling system components, etc.) are available from Mercury Precision Parts to meet your
boat rigging needs. These accessories have been carefully designed for compatibility with
Mercury MerCruiser products, providing unsurpassed quality and performance. Any
warranty problems that may occur will be quickly and conveniently handled, using the same
warranty system as used for standard Mercury products. A complete listing of all of the
latest accessories can be found in the Mercury Precision Parts and Accessories Guide.
Many of these accessories are covered under the related system sub‑sections following.
The following address and telephone numbers can be contacted for ordering parts or
obtaining technical assistance:
Inside the U.S.A.
Mercury Marine
Attn. Parts Department
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54935-1939
U.S.A.
[phone] or [phone]
Outside the U.S.A
Contact your Distribution Center or Distributor.
Factory Installed Options
Several accessories are also available as factory installed options from Mercury
MerCruiser, including (but not limited to) those listed. These factory options avoid the
problems and costs associated with installing them in your facility. Contact your sales
representative for a list of the latest options.
• Closed Cooling
• Exhaust Risers
• Propeller Shaft Couplings
• Remote Oil Filter
• Air‑Actuated Drain

Important Information
Page 1A-4 90-863758060 AUGUST 2006
Serial Number Decal Placement—Inboard and Tow Sports
There are three engine serial number decal strips provided with each power package. One
should be used for each of the following:
• Engine Specification Decal
• Warranty Registration Card
• Operation, Maintenance and Warranty Manual identification page
Affix engine serial number decal to Engine Specification Decal.
7450
a
Typical
a - Engine serial number location
11543
a
a - Engine serial number location
California Regulations for 2007—Low Permeation Fuel Hose
California Regulations for New 2007 and Later Spark-Ignition Inboard/Sterndrive
Pleasurecraft
(3) Requirements of engine manufacturers and boat manufacturers under Option 2 and
using Low Permeation Fuel Line Hose:
(A) Each manufacturer that chooses Option 2 must provide written instructions, as part of
the installation materials provided to purchasers of the engine, to use Low Permeation fuel
Line Hose for the primary Fuel line connecting the fuel tank to the engine of any boat that
is manufactured for sale, sold, or offered for sale in California, or that is introduced,
delivered or imported into California for introduction into commerce.

Important Information
90-863758060 AUGUST 2006 Page 1A-5
(B) Each boat manufactured must install Low Permeation Fuel Line Hose for the primary
Fuel line connecting the fuel tank to the engine of any boat that is manufactured for sale,
sold, or offered for sale in California that uses an engine from a manufacturer that chooses
Option 2.
Low Permeation Fuel Line Hose is defined as not exceeding 15 g/m²/24 h with CE10 fuel
at 23° C as specified in SAE J 1527—Marine Fuel Hoses.
Emission Control Information
International Regulations Compliance
In an effort to support your international business, MerCruiser spends considerable
resources each year keeping our products in compliance with international regulations. A
dedicated Regulations Group at MerCruiser is devoted to ensuring that our products meet
the host of regulatory requirements that cover our product throughout the world. This
includes compliance with the following regulations and standards:
• ABYC (American Boat and Yacht Council).
• USCG (U.S. Coast Guard).
• SAE (Society of Automotive Engineers).
• ISO (International Standards Organization).
• CARB (California Air Resources Board).
• EU (European Union).
• SAV (Schweizer Abgas Vorschriften—Swiss Gas Regulations).
• JCI (Japanese Craft Inspection).
Emission Control Information Label
A tamper‑resistant Emission Control Information label is affixed in a visible location to the
engine at time of manufacture by Mercury MerCruiser. In addition to the required emissions
statement, the label lists the engine serial number, family, FEL (emission level), date of
manufacture (month, year), and the engine displacement. Please note that the low
emissions certification will not affect the fit, function, or performance of the engines.
Boatbuilders and dealers may not remove the label or the part it is affixed to before sale.
If modifications are necessary, contact Mercury MerCruiser about the availability of
replacement decals before proceeding.
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
SERIAL# OMXXXXXXXX
FAMILY XXXXX_XXXXXX
FEL. XX.X g/kW-hr
D.O.M. JAN. 2003
DISP X.XL
11018
Emission control label — non‑CE marked
"SERIAL#" ‑ Engine serial number
"FAMILY" ‑ Engine family
"FEL." ‑ Family emission limit
"D.O.M." ‑ Date of manufacture
"DISP" ‑ Piston displacement

Important Information
Page 1A-6 90-863758060 AUGUST 2006
IMPORTANT: 5.0L, and 5.7L models are not CE certified at the time of this publication.
Contact the appropriate Mercury MerCruiser Product Application Engineers (PAE), or
Mercury MerCruiser Technical Service for information on CE certified product.
OMXXXXXX Dec 2004
X.XL
SERIAL# D.O.M.
DISP.
FAMILY
FEL.
XXXXX XXXXXX
XX.X g/kW-hr
EMISSION CONTROL
INFORMATION
THIS ENGINE CONFORMS TO 2003 CALIFORNIA EMISSION
REGULATIONS FOR SPARK IGNITION MARINE ENGINES
REFER TO OWNER'S MANUAL FOR MAINTENANCE
SPECIFICATIONS AND ADJUSTMENTS
0575
10652
Emission control label — CE marked
"SERIAL#" ‑ Engine serial number
"FAMILY" ‑ Engine family
"FEL." ‑ Family emission limit
"D.O.M." ‑ Date of manufacture
"DISP" ‑ Piston displacement
CE ‑ When this mark is present in the lower right corner of the Emission Control Information
Label, on the engine, the Declaration of Conformance applies.
NOTE: The following applies to CE marked products only.
DECLARATION OF CONFORMANCE – MERCURY MERCRUISER
This sterndrive or inboard engine when installed in accordance to Mercury MerCruisers’
instructions complies with the requirements of the following directives by meeting the
associated standards, as amended:
Recreational Craft Directive 94/25/EC; 2003/44/EC
Applicable Requirement Standards Applied
Owner’s manual (A.2.5) ISO 10240
Openings in Hull, Deck and superstructure (A.3.4) ISO 9093‑1; ISO 9093‑2
Handling characteristics (A.4) ISO 8665
Inboard Engine (A.5.1.1) ISO 15584; ISO 10088; ISO 7840; ISO 10133
Fuel System (A.5.2) ISO 10088; ISO 7840; ISO 8469
Electrical System (A.5.3) ISO 10133; ISO 8846
Steering system (A.5.4) Applicable portions of: ISO 10592, ISO 8848 and
ABYC P‑17
Exhaust emission requirements (B.2) ISO 8178
Owner’s manual (B.4) ISO 8665
Noise emission levels (C.1) ISO 14509
Ignition‑protected equipment (Annex II) ISO 8846; SAE J1171; SAE J1191; SAE J 2031

Important Information
90-863758060 AUGUST 2006 Page 1A-7
Mercury MerCruiser declares that our sterndrive or inboard engines without integral
exhaust, when installed in a recreational craft, in accordance with the manufacturers
supplied instructions, will meet the exhaust emissions requirements of the directive
mentioned above. This engine must not be put into service until the recreational craft in
which it is to be installed has been declared in conformity, if so required, with the relevant
provision of the directive.
Electromagnetic Compatibility Directive 89/336/EC, 92/31/EEC and 93/68/EEC
Generic emission standard EN 50081‑1
Generic immunity standard EN 50082‑1
Vehicles, boats and internal combustion engine
driven devices ‑ Radio disturbance characteristics SAE J551 (CISPR 12)
Electrostatic discharge testing EN 61000‑6‑2; EN 61000‑4‑2; EN61000‑4‑3
The notified body responsible for surveillance of the quality system under Full Quality Assurance Module H
of Directive 2003/44/EC is:
Det Norske Veritas
Norway
Notified Body Number: 0575
This declaration is issued under the sole responsibility of Mercury Marine and Mercury MerCruiser.
Patrick C. Mackey
President ‑ Mercury Marine, Fond du Lac, WI USA
Regulatory contact:
Engineering - Regulatory
MerCruiser
3003 N. Perkins Rd
Stillwater, Oklahoma 74075
USA
[phone]
RECREATIONAL CRAFT DIRECTIVES—EU
REQUIREMENTS FOR BOAT COMPANIES
•Craft requirements as stated in Annex I of the Recreational Craft Directives require
adding the CE marking to the builder's plate (capacity plate), not the HIN plate.
• Adherence to all component requirements as stated in Annex II of the Recreational
Craft Directives.
Mercury Marine will meet the amended Recreational Craft Directives for all Mercury
Outboard and Mercruiser product equipped with integral exhaust.
Boats that are equipped with non integral exhaust (after market exhaust) must be tested
and certified by the boat manufacturer for conformance with requirements as stated in
Annex I of the Recreational Craft Directives. The boat must be equipped with the intended
exhaust system at the time of testing.
Boats produced in the US must clear customs on EU soil by 12/31/2005 at the latest to be
exempt from 2006 requirements.
OWNER RESPONSIBILITY
The owner is required to have routine engine maintenance performed to maintain emission
levels within prescribed certification standards.

Important Information
Page 1A-8 90-863758060 AUGUST 2006
The owner is not to modify the engine in any manner that would alter the horsepower or
allow emissions levels to exceed their predetermined factory specifications.
Star Label
Beginning January 1, 2003, one Three‑Star label will be included with each factory‑certified
Mercury MerCruiser engine.
All Mercury MerCruiser engines (500 hp and below) will have a Three‑Star Ultra Low
Emission rating. The Three‑Star label identifies that these engines meet the California Air
Resources Board's Sterndrive and Inboard marine engine 2003 exhaust emission
standards. Engines meeting these standards have 65% lower emissions than One‑Star ‑
Low Emissions engines.
The Three‑Star label will be affixed on the left side of the hull as shown.
XX 1234 XX
mc79531
ab
a - Recommended location b - Secondary location

Important Information
90-863758060 AUGUST 2006 Page 1A-9
One Star - Low emission
mc79569-1
The one‑star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air Resources
Board's Personal Watercraft and Outboard marine engine
2001 exhaust emission standards. Engines meeting these
standards have 75% lower emissions than conventional
carbureted two‑stroke engines. These engines are
equivalent to the U.S. EPA's 2006 standards for marine
engines.
Two Stars - Very Low emission
FO
IDA
mc79570-1
The two‑star label identifies personal watercraft, outboard,
sterndrive and inboard engines that meet the Air Resources
Board's Personal Watercraft and Outboard marine engine
2004 exhaust emission standards. Engines meeting these
standards have 20% lower emissions than One Star ‑
Low‑Emission engines.
Three Stars - Ultra Low emission
A
SS
D
mc79571-1
The three‑star label identifies engines that meet the Air
Resources Board's Personal Watercraft and Outboard
marine engine 2008 exhaust emission standards or the
Sterndrive and Inboard marine engine 2003 exhaust
emission standards. Engines meeting these standards
have 65% lower emissions than One Star ‑ Low Emission
engines.
Four Stars - Super Ultra Low emission
RN
F
T
mc79572-1
The Four Star label identifies engines that meet the Air
Resources Board's Sterndrive and Inboard marine engine
2009 exhaust emission standards. Personal Watercraft and
Outboard marine engines may also comply with these
standards. Engines meeting these standards have 90%
lower emissions than One Star ‑ Low Emission engines.

Important Information
Page 1A-10 90-863758060 AUGUST 2006
Specifications
Engine Specifications
TOW SPORTS MODELS
5.7L 350 MAG MPI Black
Scorpion MX 6.2L MPI MX 6.2 Black Scorpion
Propshaft Power 201 kw
(270 hp)
235 kw
(315 hp)
246 kw
(330 hp)
239 kw
(320 hp)
254 kw
(340 hp)
Displacement 5.7 liter (350 cid) 6.2 liter (377 cid)
Configuration /
Cylinders V‑8
Bore x Stroke 102 x 88.4 mm (4.00 x 3.48 in.) 102 x 95.3 mm (4.00 x 3.75 in.)
Compression Ratio 9.4:1 9.0:1
Fuel System 2 Bbl. Carb (TKS) MPI
Ignition System Digital
Thunderbolt 5 ECM 555
Alternator Amp.
Cold/Hot 72 amp. / 65 amp.
Maximum RPM @
WOT 4400–4800 4600–5000 4800–5200
Rev Limiter RPM 4950 5150 5350
Idle RPM 650
Oil Pressure @ 2000
RPM 207–483 kPa (30–70 psi)
Minimum Oil
Pressure @ Idle
28 kPa
(4 psi)
41 kPa
(6 psi)
28 kPa
(4 psi)
41 kPa
(6 psi)
Thermostat
Temperature 71 °C (160 °F) (Seawater Cooled)
Timing (Degrees) 10° BTDC 8° BTDC
Firing Order 1‑8‑4‑3‑6‑5‑7‑2
Weight 375 kg
(833 lb.)
365 kg
(813 lb.)
373 kg
(821 lb.)
373 kg
(821 lb.)
373 kg
(821 lb.)
Closed Cooling N/A
Remote Oil Line Optional Optional
Audio Warning
System Standard
Water Drain System Multi‑point Manual
Air Actuated
Water Drain
optional
Multi‑point
Manual
Air Actuated
Water Drain
optional
50 Amp Circuit
Breaker Standard
Minimum Battery
Rating
375 cca / 475
mca / 90 Ah 750 cca / 950 mca / 180 Ah
Flush System Kit
S Pipe Exhaust N/A Optional N/A Optional N/A
Optional Riser Kits 43 mm (1.7 in.) N/A 43 mm (1.7 in.) N/A

Important Information
90-863758060 AUGUST 2006 Page 1A-11
INBOARD MODELS BELOW 239 KW (320 HP)
5.7L 350 MAG MPI 350 MAG MPI Horizon
Propshaft Power 194 kw (260 hp) 224 kw (300 hp) 224 kw (300 hp)
Displacement 5.7 liter (350 cid)
Configuration / Cylinders V‑8
Bore x Stroke 102 x 88.4 mm (4.00 x 3.48 in.)
Compression Ratio 9.4:1
Fuel System 2 Bbl. Carb. MPI
Ignition System Thunderbolt 5 Digital Digital
Alternator Amp. (Cold/Hot) 72 amp / 65 amp
Maximum RPM at WOT 4200–4600 4600–5000
Rev Limiter RPM 4750 5150
Idle RPM 650 600
Oil Pressure @ 2000 RPM 30‑70 psi / 207‑483 kPa
Min. Oil Pressure @ Idle 4 psi / 28 kPa
Thermostat Temperature 71°C (160°F) (Seawater Cooled)
Thermostat Temperature 77°C (170°F) (Closed Cooled)
Timing 10° BTDC 8° BTDC
Firing Order 1‑8‑4‑3‑6‑5‑7‑2
Transmission Offerings Refer to SECTION 2‑Transmission and Drive Line
Weight 400 kg (888 lb.) 390 kg (860 lb.) 427 kg (948 lb.)
Remote Oil Not Available Standard
Closed Cooling Kit Optional Standard
Audio Warning System Standard
Water Drain System Multipoint Drain System
Multipoint Drain System
standard
Air Actuated Water
Drain is optional for
Closed Cooling models
Air Actuated Water
Drain
50 Amp Circuit Breaker Standard
Flush System Kit Standard
Exhaust Elbows Cast Iron w/Ceramic, EDP and Paint
Optional Riser Kits 43 mm (1.7 in.) 76 mm (3 in.), 152 mm (6 in)
Battery rating 375 cca / 475 mca / 90 Ah 750 cca / 950 mca / 180 Ah (Minimum rating)
Battery rating for DTS models N/A 800 cca / 1000 mca / 190 Ah (Minimum rating)

Important Information
Page 1A-12 90-863758060 AUGUST 2006
INBOARD MODELS OVER 224 KW (300 HP)
MX 6.2 MPI MX 6.2 MPI
Horizon 8.1S HO 8.1S Horizon
Propshaft Power 239 kw (320 hp) 313 kw (420 hp) 276 kw (370 hp)
Displacement 6.2 liter (377 cid) 8.1 liter (496 cid)
Configuration /
Cylinders V‑8
Bore x Stroke 102 ‑ 95.3 mm (4.00 x 3.75 in.) 108 x 111 mm (4.25 x 4.38 in.)
Compression Ratio 9.0:1 9.1:1
Fuel System MPI
Ignition System Digital Distributorless
Alternator Amp.
(Cold/Hot) 72 amp / 65 amp
Maximum RPM at
WOT 4600–5000 4400–4800 4200–4600
Rev Limiter RPM 5150 4950 4750
Idle RPM 600 650
Oil Pressure @ 2000
RPM 207–483 kPa (30–70 psi) 413 kPa (60 psi)
Minimum Oil
Pressure @ Idle 28 kPa (4 psi) 207 kPa (30 psi)
Thermostat
Temperature 71°C (160°F) (Seawater Cooled) N/A
Thermostat
Temperature 77°C (170°F) (Closed Cooling) 71°C (160°F) (Closed Cooling)
Timing 8° BTDC N/A
Firing Order 1‑8‑4‑3‑6‑5‑7‑2 1‑8‑7‑2‑6‑5‑4‑3
Transmission
Offerings Refer to SECTION 2‑Transmission and Drive Line
Dimensions Refer to Installation CD
Weight 390 kg (860 lb.) (with down angle transmission) 513 kg (1130 lb.) (with down
angle transmission)
Remote Oil Standard
Closed Cooling Optional Standard
Audio Warning
System Standard
Water Drain System
Multipoint Drain System Standard
Air Actuated Water Drain is
optional with Closed Cooling
Air Actuated Water Drain
50 Amp Circuit
Breaker Standard
Flush System Standard Kit Kit
Optional Riser Kits 43 mm (1.7 in.) 76 mm (3 in.) 152 mm (6 in.) 51 mm (2 in.) 152 mm
(6 in.) 203 mm (8 in.)
Battery rating 750 cca / 950 mca / 180 Ah (Minimum rating)
Battery rating for DTS
models 800 cca / 1000 mca / 190 Ah (Minimum rating)

Important Information
90-863758060 AUGUST 2006 Page 1A-13
Torque Specifications
NOTE: Securely tighten all fasteners not listed below.
Description Nm lb. in. lb. ft.
Engine mount bracket screws 64 47
Trunnion clamping screws and nuts 68 50
Thermostat housing attaching screws 41 30
Propeller shaft coupling screws and nuts 68 50
Shift and throttle cable fasteners Tighten securely, then loosen ½ turn to
allow pivot points to rotate
Fuel inlet fitting (water separator)
Apply #567 loctite pipe sealant with
teflon to threads.
Do not use teflon tape.
1¾ to 2¼ turns past finger tight.

Important Information
Notes:
Page 1A-14 90-863758060 AUGUST 2006

Transmission and Drive Line
90-863758060 AUGUST 2006 Page 2A-1
2
A
Transmission and Drive Line
Section 2A - Transmission and Drive Line
Table of Contents
General Information.........................................2A-2
Gear Ratio Selection.................................2A-2
Engine and Propeller Shaft Installation Angle
..................................................................2A-2
Propeller Shaft Rotation and Spacing on Dual
Installations...............................................2A-2
Propeller Blade Tip Clearance..................2A-3
Propeller Shaft Coupling...........................2A-3
Propeller Shaft..........................................2A-4
Propeller Shaft Log Seal Connections.............2A-4
Transmissions..................................................2A-6
Gear Ratios...............................................2A-6
Model Offerings and Identification............2A-7
Propeller Rotation...................................2A-10
ZF Marine Transmissions—DTS....................2A-12
Remote Control and Shift Cable....................2A-13